{"title":"Corrosion degradation and interface behaviour of magnetron sputtered NiAl coatings doped with Zr, Hf, and Cr","authors":"Shen Tao , Hui Peng , Hongbo Guo","doi":"10.1016/j.corsci.2025.113324","DOIUrl":null,"url":null,"abstract":"<div><div>In this work, NiAl-based coatings doped with optimised Zr, Hf, and Cr content are deposited via magnetron sputtering and evaluated for hot corrosion performance. Systematic high-temperature corrosion tests and microstructural analyses reveals that the corrosion resistance and oxide scale adherence of the coatings are strongly dependent on the dopant type and content. Among the single-element doped coatings, NiAlZr exhibits the highest corrosion resistance but suffers from poor scale adhesion, whereas NiAlCr shows the lowest corrosion resistance yet excellent adhesion due to the formation of porous internal and external oxide layers. NiAlHf coating demonstrates intermediate performance. Mechanistically, Zr/ZrO<sub>2</sub> particles effectively suppress the β→γ/γ′ phase transformation and stabilise the grain structure, while HfO<sub>2</sub> promotes interfacial transitions that improves scale anchoring. The presence of Cr will reduce the lattice mismatch but potentially disrupted γ′ ordering. Furthermore, surface wettability and roughness are observed to govern salt mist deposition behaviour, with smoother, more hydrophobic coatings (NiAlZr and NiAlHf) resisting salt accumulation. Notably, a significant synergistic effect between Zr and Hf identified in co-doped NiAlZrHf coating, which outperforms the single-doped counterparts. These findings offer insights into compositional tailoring strategies for enhancing hot corrosion resistance in advanced aluminide coatings.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113324"},"PeriodicalIF":7.4000,"publicationDate":"2025-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Corrosion Science","FirstCategoryId":"88","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S0010938X25006523","RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"MATERIALS SCIENCE, MULTIDISCIPLINARY","Score":null,"Total":0}
引用次数: 0
Abstract
In this work, NiAl-based coatings doped with optimised Zr, Hf, and Cr content are deposited via magnetron sputtering and evaluated for hot corrosion performance. Systematic high-temperature corrosion tests and microstructural analyses reveals that the corrosion resistance and oxide scale adherence of the coatings are strongly dependent on the dopant type and content. Among the single-element doped coatings, NiAlZr exhibits the highest corrosion resistance but suffers from poor scale adhesion, whereas NiAlCr shows the lowest corrosion resistance yet excellent adhesion due to the formation of porous internal and external oxide layers. NiAlHf coating demonstrates intermediate performance. Mechanistically, Zr/ZrO2 particles effectively suppress the β→γ/γ′ phase transformation and stabilise the grain structure, while HfO2 promotes interfacial transitions that improves scale anchoring. The presence of Cr will reduce the lattice mismatch but potentially disrupted γ′ ordering. Furthermore, surface wettability and roughness are observed to govern salt mist deposition behaviour, with smoother, more hydrophobic coatings (NiAlZr and NiAlHf) resisting salt accumulation. Notably, a significant synergistic effect between Zr and Hf identified in co-doped NiAlZrHf coating, which outperforms the single-doped counterparts. These findings offer insights into compositional tailoring strategies for enhancing hot corrosion resistance in advanced aluminide coatings.
期刊介绍:
Corrosion occurrence and its practical control encompass a vast array of scientific knowledge. Corrosion Science endeavors to serve as the conduit for the exchange of ideas, developments, and research across all facets of this field, encompassing both metallic and non-metallic corrosion. The scope of this international journal is broad and inclusive. Published papers span from highly theoretical inquiries to essentially practical applications, covering diverse areas such as high-temperature oxidation, passivity, anodic oxidation, biochemical corrosion, stress corrosion cracking, and corrosion control mechanisms and methodologies.
This journal publishes original papers and critical reviews across the spectrum of pure and applied corrosion, material degradation, and surface science and engineering. It serves as a crucial link connecting metallurgists, materials scientists, and researchers investigating corrosion and degradation phenomena. Join us in advancing knowledge and understanding in the vital field of corrosion science.